Self cleaning sump cover

ABSTRACT

A fluid flow system for a laundry appliance includes a blower that delivers process air along an airflow path having a heat exchanger. A drain channel receives condensate from the heat exchanger and fluid spray from a spray nozzle for directing lint particles to the drain channel and on to a sump for collecting fluid, including the condensate. A pump seat and a fluid outlet are integrally formed in a sump cover. A pump directs the fluid from the sump to the fluid outlet. A fluid level sensor detects at least minimum and maximum capacities of the fluid in the sump. When the fluid is below the minimum capacity, the pump defines an idle state. When the fluid reaches the minimum capacity, the pump defines an active state. When the fluid exceeds the maximum capacity, the pump directs the fluid to the fluid outlet.

CROSS-REFERENCE To RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 15/830,540 filed Dec. 4, 2017, entitled SELF CLEANING SUMP COVER,which claims priority to and the benefit under 35 U.S.C. § 119(e) ofU.S. Provisional Patent Application No. 62/464,055, filed on Feb. 27,2017, entitled SELF-CLEANING LINT FILTER FOR A LAUNDRY APPLIANCE HAVINGA HEAT PUMP SYSTEM, and U.S. Provisional Patent Application No.62/561,901, filed on Sep. 22, 2017, entitled SELF-CLEANING LINT FILTERFOR A LAUNDRY APPLIANCE HAVING A HEAT PUMP SYSTEM, and U.S. ProvisionalPatent Application No. 62/572,794, filed on Oct. 16, 2017, entitledSELF-CLEANING LINT FILTER FOR A LAUNDRY APPLIANCE HAVING A HEAT PUMPSYSTEM, the entire disclosures of which are hereby incorporated hereinby reference.

FIELD OF THE DEVICE

The device is in the field of laundry appliances, more specifically, alaundry appliance that includes a self-cleaning lint filter for removinglint from process air before reaching a heat pump system.

SUMMARY

In at least one aspect, a fluid flow system for a laundry applianceincludes a blower that delivers process air along an airflow path. Aheat exchanger dehumidifies the process air and removes condensatetherefrom. A drain channel receives the condensate from the heatexchanger and fluid spray from a spray nozzle for directing lintparticles to the drain channel. A sump collects fluid from the drainchannel. The fluid at least partially includes the condensate. A sumpcover includes a pump seat, and a fluid outlet that are integrallyformed in the sump cover. A pump directs the fluid from the sump and tothe fluid outlet. A fluid level sensor detects at least a minimumcapacity and a maximum capacity of the fluid in the sump. When the fluidis below the minimum capacity, the pump defines an idle state. When thefluid reaches the minimum capacity, the pump defines an active state.When the fluid exceeds the maximum capacity, the pump directs a flow ofthe fluid to the fluid outlet of the sump cover.

In at least another aspect, a fluid flow system for a laundry applianceincludes a blower that delivers process air along an airflow path duringperformance of a drying operation. A heat exchanger dehumidifies theprocess air and removes condensate therefrom. A lint filter is includedfor capturing lint particles from the process air, wherein a fluid spraysystem removes the lint particles from the lint filter. A sump collectsthe condensate from the heat exchanger and lint particles from the fluidspray system to define sump fluid within the sump. A sump cover has apump that directs the sump fluid from the sump and to a fluid divertervalve, and a fluid level sensor that at least partially operates thepump. The pump and the fluid level sensor are directly attached to thesump cover. The pump activates when a level of the sump fluid reaches amaximum capacity within the sump. The pump remains idle when the levelof the sump fluid is below a minimum capacity.

In at least another aspect, a method for operating a fluid flow systemfor an appliance includes performing a drying operation. Sump fluid isdelivered to a sump. The sump fluid includes condensate from a heatexchanger and lint particles from a fluid spray system. A level of thesump fluid in the sump is detected, wherein a sump pump remains idleduring the drying operation when the level of the sump fluid is below aminimum capacity. A spray sequence is performed after the level of thesump fluid reaches the minimum capacity. The spray sequence directs thesump fluid to remove the lint particles from a surface and direct thelint particles and the sump fluid to the sump. The sump fluid containingthe lint particles is recirculated during the spray sequence. The sumpfluid is directed from the sump, to a spray nozzle via a fluid divertervalve, and back to the sump. The method also includes completing thespray sequence, completing the drying operation and operating a drainphase of the pump to deliver the sump fluid to a removable bottle aftercompletion of the drying operation.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a laundry appliance incorporatingan aspect of a heat pump system;

FIG. 2 is a cross-sectional view of the appliance of FIG. 1 taken alongline II-II;

FIG. 3 is a cross-sectional view of the appliance of FIG. 1 taken alongline III-III;

FIG. 4 is a schematic view of a laundry appliance incorporating anaspect of the heat pump system and an aspect of the self-cleaning lintfilter;

FIG. 5 is a top perspective view of a heat pump system for a laundryappliance;

FIG. 6 is a second top perspective view of the heat pump system of FIG.5;

FIG. 7 is a top plan view of the heat pump system of FIG. 5;

FIG. 8 is a top perspective view of the heat pump system of FIG. 5 withthe heat exchangers removed;

FIG. 9 is a cross-sectional view of the heat pump system of FIG. 7 takenalong line IX-IX;

FIG. 10 is a cross-sectional view of the heat pump system of FIG. 7taken along line X-X during activation of the first spray nozzle;

FIG. 11 is a top plan view of a condensate flow system for a laundryappliance;

FIG. 12 is a top perspective view of an aspect of a heat exchangersupport plate for use in connection with a heat pump system for alaundry appliance;

FIG. 13 is a top perspective view of the heat exchanger support plate ofFIG. 12;

FIG. 14 is a top perspective view of a fluid nozzle for use inconjunction with the self-cleaning lint filter;

FIG. 15 is a top plan view of the fluid nozzle of FIG. 14;

FIG. 16 is a side elevational view of the fluid nozzle of FIG. 14;

FIG. 17 is a rear elevational view of the fluid nozzle of FIG. 14;

FIG. 18 is a schematic diagram illustrating operation of the pump anddiverter valve for the condensate flow system and lint removal system;

FIG. 19 is a schematic flow diagram illustrating a method for operatinga spray sequence for cleaning a lint filter within a heat pump system;

FIG. 20 is a top perspective view of an aspect of the diverter valve foruse in connection with the heat pump system;

FIG. 21 is a top plan view of an aspect of the diverter valve for use inconnection with the heat pump system;

FIG. 22 is a cross-sectional view of the diverter valve of FIG. 20,taken along line XXII-XXII and showing the diverter valve in a cleaningphase;

FIG. 23 is a cross-sectional view of the diverter valve of FIG. 20 takenalong line XXIII-XXIII and showing the diverter valve in a drain phase;

FIG. 24 is a schematic flow diagram illustrating a method for operatinga lint removal system for an appliance;

FIG. 25 is a top perspective view of a basement for a laundry applianceand showing an aspect of a sump cover for housing a sump pump of theappliance;

FIG. 26 is a partially exploded view of the sump cover of FIG. 25 shownremoved from a sump portion of the basement for the laundry appliance;

FIG. 27 is a bottom perspective view of an aspect of a sump cover thatincorporates a fluid level sensor;

FIG. 28 is a top perspective view of the sump cover of FIG. 27;

FIG. 29 is a partially exploded side perspective view of the sump coverof FIG. 27;

FIG. 30 is a top perspective view of a basement for a laundry applianceand showing an aspect of a lint filter positioned upstream of a heatexchanger;

FIG. 31 is a rear perspective view of an aspect of a basement for theappliance showing the heat exchangers removed and illustrating an aspectof the lint filter;

FIG. 32 is a top perspective view of an aspect of the lint filter;

FIG. 33 is a front elevational view of the lint filter of FIG. 32;

FIG. 34 is a rear elevational view of the lint filter of FIG. 32;

FIG. 35 is a schematic perspective view of a front side of the lintfilter;

FIG. 36 is a schematic perspective view of a rear side of the lintfilter of FIG. 35;

FIG. 37 is a cross-sectional view of the lint filter of FIG. 30 takenalong line XXXVII-XXXVII;

FIG. 38 is an enlarged cross-sectional view of the lint filter of FIG.37 taken at area XXXVIII;

FIG. 39 is an enlarged cross-sectional view of the lint filter of FIG.37 taken at area XXXIX;

FIG. 40 is a cross-sectional view of the lint filter of FIG. 30 taken atline XL-XL;

FIG. 41 is a cross-sectional view of the lint filter of FIG. 31 taken atline XLI-XLI;

FIG. 42 is a side perspective view of a basement for a laundry applianceshowing an aspect of a lint filter positioned upstream of a heatexchanger;

FIG. 43 is a partially exploded view of the basement of FIG. 42 showingthe lint filter removed from the lint filter receptacle;

FIG. 44 is a cross-sectional view of the basement of FIG. 42 taken alongline XLIV-XLIV;

FIG. 45 is a perspective view of an aspect of a sump cover incorporatinga multi-component fluid level sensor for operating a sump pump; and

FIG. 46 is a schematic cross-sectional view of a sump for a laundryappliance that includes an aspect of the multi-component fluid levelsensor and exemplifying operation of the pump in relation to themulti-component fluid level sensor.

DETAILED DESCRIPTION OF EMBODIMENTS

As illustrated in FIGS. 1-4, reference numeral 10 generally refers to aheat pump system for use in a laundry appliance 12, typically a laundrydrying appliance 12. The laundry appliance 12 can include a drum 14 forprocessing laundry articles 16 contained therein. The drum 14 isrotationally operable within a cabinet 18 that serves as a housing forthe components of the laundry appliance 12. An airflow path 20 isincluded within the cabinet 18 and includes a blower 22 that movesprocess air 24 through the airflow path 20 and also through the drum 14.Accordingly, process air 24 can be moved through the drum 14 for dryingor otherwise processing damp or wet articles 16 that may be containedwithin the drum 14. The heat pump system 10 is at least partiallypositioned within the airflow path 20. The heat pump system 10 caninclude at least one heat exchanger 26 that receives process air 24 fromthe drum 14 through operation of the blower 22. The blower 22 can belocated upstream of the heat exchangers 26 such that operation of theblower 22 pushes the process air 24 toward and through the heatexchangers 26. The blower 22 can also be located downstream of the heatexchangers 26. In this configuration, operation of the blower 22 drawsthe process air 24 through the heat exchangers 26. One or more blowers22 may be located either upstream or downstream of the heat exchangers26. There may also be multiple blowers 22 that can be located bothupstream and downstream of the heat exchangers 26.

Referring again to FIGS. 1-4, during a performance of a drying function30 of the appliance 12, the at least one heat exchanger 26 can receivemoisture-laden air 32 from the drum 14. The heat exchanger 26, typicallyan evaporator 34, can reduce the temperature of the moisture-laden air32. By reducing the temperature of the moisture-laden air 32, theprocess air 24 is dehumidified and condensate 36 is precipitated out ofthe moisture-laden air 32. Once precipitated, this precipitated moistureis removed from the moisture-laden air 32 as condensate 36 that fallsfrom the heat exchanger 26. A drain channel 38 is positioned below theheat exchanger 26 and serves to capture the condensate 36. After thecondensate 36 has been removed, the process air 24 continues through theairflow path 20 back to the drum 14 to continue the drying function 30of the laundry appliance 12.

The heat pump system 10 can also include a condenser 40 that serves toheat the now dehumidified process air 24 after moving through theevaporator 34. Accordingly, the heat pump system 10 can serve to modifythe temperature of the process air 24 to perform various cooling andheating operations through use of the evaporator 34 and condenser 40,respectively, to dry the damp articles 16 within the drum 14. Additionalheaters, such as electric heaters, can also be included to modify thetemperature of the process air 24.

As exemplified in FIGS. 1-4, after the condensate 36 is removed from themoisture-laden air 32 and is moved to the drain channel 38, a pump 50connected to the drain channel 38 is adapted to deliver the condensate36 from the drain channel 38 to separate locations. These separatelocations can be in the form of various spray nozzles 52 for cleaningone or more internal lint filters 54, an internal removable bottle 56that can be removed after operation of the laundry appliance 12, as wellas others. This location can also be in the form of an external drainwhere condensate 36 and other material can be moved by the pump 50 fromthe drain channel 38 to the exterior drain.

Where the condensate 36 is moved to the spray nozzles 52 and to theremovable bottle 56 contained within the cabinet 18, a diverter valve 58is connected to the pump 50. This diverter valve 58 serves to deliverthe condensate 36 to various locations within the appliance 12 dependingon the position of the diverter valve 58. As will be described morefully below, the diverter valve 58 is operable to define a cleaningphase 60, where condensate 36 is moved to the spray nozzles 52 forcleaning the internal lint filter 54. The diverter valve 58 can also bemoved to a drain phase 62 where condensate 36 from the drain channel 38as well as lint particles 64 and other particulate matter are movedthrough the pump 50 and through the diverter valve 58 for disposal ofthe condensate 36 and lint particles 64 into the removable bottle 56.

Referring again to FIGS. 1-4, as the process air 24 moves through thedrum 14 for drying the damp articles 16 contained therein, the processair 24 can also pick up lint particles 64, such as fluff and otherparticulate matter, along with the moisture removed from the damparticles 16 within the drum 14. Accordingly, the moisture-laden air 32moved from the drum 14 and toward the evaporator 34 also contains acertain amount of lint particles 64. In order to prevent, orsubstantially prevent, these lint particles 64 from reaching theevaporator 34 or other parts of the heat pump system 10, one or more airfilters 70 are disposed within the airflow path 20 for cleaning themoisture-laden air 32 before it reaches the evaporator 34.

One such air filter 70 can include a removable lint filter 72 that ispositioned proximate a door 74 of the cabinet 18. The removable lintfilter 72 is typically positioned within an opening 76 for the door 74of the appliance 12 and is adapted to be removed from a filter housing78 by hand and without the use of tools. This removable lint filter 72can include a single lint filtering layer 80 that captures lintparticles 64 from the moisture-laden air 32 and entraps the lintparticles 64 within a filtering material 82. This filtering material 82can take the form of a mesh screen, foam-type filter, combinationsthereof and other similar filtering material 82.

The removable lint filter 72 can include a single filtering layer 80 orcan contain a plurality of filtering layers 80. Where a plurality offiltering layers 80 are included within the removable lint filter 72,each of the filtering layers 80 can contain an identical filteringmaterial 82 with the same filtering capability. Alternatively, thefiltering layers 80 can be oriented such that each successive filteringlayer 80 contains a decreasing mesh size or pore size. In this manner,each successive layer of filtering material 82 of the removable lintfilter 72 can entrap progressively smaller lint particles 64 from themoisture-laden air 32. Through the use of the removable lint filter 72,a majority of the lint particles 64 contained within the moisture-ladenair 32 is designed to be entrapped by the removable lint filter 72. Theremovable lint filter 72 can include a single planar filter, multipleplanar filters, planar filters oriented in a “V” or “U” configuration,as well as other similar configurations adapted to allow moisture-ladenprocess air 24 to pass therethrough for entrapping lint particles 64within the filtering material 82 of the removable lint filter 72.

In various embodiments of the device, the filtering material 82 can bein the form of a fluid that is sprayed through a portion of the airflowpath 20. As this fluid is sprayed from the airflow path 20, the fluidwets portions of the lint particles 64 within the moisture-laden air 32.This moistened particulate matter increases in weight and may fall fromthe moisture-laden air 32 into a separate area defined within orattached to the airflow path 20. These wetted lint particles 64 can thenbe moved from the drain channel 38 for further disposal.

Referring now to FIGS. 2-11, the lint removal system 90 can include aninternal lint filter 54 that is positioned within the airflow path 20and between the removable lint filter 72 and the evaporator 34 of theheat pump system 10. The internal lint filter 54 includes a filteringmaterial 82 with a mesh size or pore size that is typically smaller thanthe corresponding mesh size or pore size of the filtering layers 80included within the removable lint filter 72. Accordingly, the removablelint filter 72 and the internal lint filter 54 cooperate to filter outand remove progressively smaller sized lint particles 64 as themoisture-laden air 32 moves toward the evaporator 34. The use ofprogressively smaller mesh sizes or pore sizes of the filtering material82 within the lint removal system 90 allows for the capturing of largerlint particles 64 at the initial filter, typically the removable lintfilter 72. Because the mesh size of the removable lint filter 72 is onlyadapted to capture lint particles 64 of a particular size, smaller lintparticles 64 are allowed to pass through the filter material of theremovable lint filter 72. This serves to limit excessive blockage bylint particles 64 and other particulate material within any one airfilter 70 of the lint removal system 90. Typically, the removable lintfilter 72 is adapted to catch the largest amount of lint particles 64.Each subsequent air filter 70 from the moisture-laden air 32 is designedto capture smaller lint particles 64 and, in turn, smaller quantities oflint particles 64. Through this system, each air filter 70 is designedto capture an appropriate quantity of lint particles 64 that prevents atotal blockage of any one of the air filters 70 along the lint removalsystem 90.

Referring again to FIGS. 2-11, the internal lint filter 54 can include asingle filtering member, typically, a single lint screen 100 that ispositioned upstream of the evaporator 34. The internal lint filter 54can also include multiple lint screens 100. As discussed above, eachsubsequent lint screen 100 is designed to capture smaller lint particles64. In this manner, substantially all of the lint particles 64 from themoisture-laden air 32 can be captured within at least one of the airfilters 70, either the removable lint filter 72 or an internal lintfilter 54, of the lint removal system 90.

As exemplified in FIGS. 2-11, the removable lint filter 72 is adapted tobe removed by hand and without the use of tools after each drying cycleperformed by the appliance 12. Conversely, the internal lint filter 54is typically designed to stay in a fixed position during regular use.While periodic cleaning of the internal lint filter 54 is provided for,such cleaning is typically designed to be performed by a professionaltechnician. Such professional cleaning may be necessary for maintainingthe heat pump system 10 and the lint removal system 90 and may occurannually, every two or more years, every six months, or other timeperiod.

Referring again to FIGS. 1-11, the internal lint filters 54 are adaptedto be cleaned through operation of the appliance 12 by using thecondensate 36 that is collected within the drain channel 38. Asdiscussed above, this condensate 36 is moved from the drain channel 38by activation of a pump 50 coupled to the drain channel 38. The pump 50moves this condensate 36 to the diverter valve 58. When the divertervalve 58 is in the cleaning phase 60, the condensate 36 moves throughthe diverter valve 58 and is directed to a fluid spray system 110 thatsprays condensate 36 onto a surface of the internal lint filter 54. Thisfluid spray 112 from the nozzles of the fluid spray system 110 serves topush lint particles 64 off from a front surface 114 of the internal lintfilter 54. The fluid spray 112 also pushes the lint particles 64downward and into the drain channel 38.

Typically, the internal lint filter 54 will be served by at least twoseparate spray nozzles 52 for directing the fluid spray 112 to a surfaceof the internal lint filter 54. Additionally, where multiple internallint filters 54 are included, each internal lint filter 54 willtypically be served by at least two spray nozzles 52 for directing thefluid spray 112. During operation, the internal lint filter 54 will besprayed by only one of the two spray nozzles 52, being first and secondnozzles 116, 118, at any one time. As condensate 36 is sprayed from oneof the first and second nozzles 116, 118, condensate 36 may becometemporarily entrapped within a portion of the filter material. Thistemporarily trapped condensate 120 can cause a temporary blockage ofprocess air 24 moving through that portion of the internal lint filter54. The unsprayed portion 122 of the internal lint filter 54 remainssubstantially unblocked such that moisture-laden process air 24 isallowed to continue to pass therethrough. The temporarily trappedcondensate 120 within the sprayed portion 124 of the internal lintfilter 54 is eventually pushed out by the process air 24, evaporated, orotherwise removed from the lint screen 100 such that process air 24 canmove therethrough to continue filtering lint particles 64. Afteroperation of the first nozzle 116 to clean the first portion 126 of theinternal lint filter 54, and removal of any trapped condensate 120therefrom, the second nozzle 118 is then activated to remove lintparticles 64 from the second portion 128 of the internal lint filter 54.As with the first nozzle 116, the second nozzle 118 sprays condensate36, in the form of a fluid spray 112, to push lint particles 64 downwardand into the drain channel 38 for ultimate removal from the appliance12.

During operation of the first and second nozzles 116, 118 of the fluidspray system 110, condensate 36 can be sprayed onto the front surface114 of the internal lint filter 54. In such an embodiment, the first andsecond nozzles 116, 118 are directed to push lint particles 64 off fromthe front surface 114 of the internal lint filter 54, such that thesprayed condensate 142 and lint particles 64 can be captured within thedrain channel 38. The first and second nozzles 116, 118 of the fluidspray system 110 can also be oriented to spray condensate 36 through theback surface 140 of the internal lint filter 54 to push lint particles64 off from the front surface 114 of the internal lint filter 54 wherethe sprayed condensate 142 and lint particles 64 can be captured withinthe drain channel 38. In various embodiments, a combination of spraynozzles 52 that spray both the front and back surfaces 114, 140 of theinternal lint filter 54 can also be implemented.

As exemplified in FIGS. 2-11, to operate the first and second nozzles116, 118, or any additional spray nozzles 52 that may be included withinthe fluid spray system 110, the diverter valve 58 can include aplurality of cleaning phase positions 150. Each cleaning phase position150 can correspond to one spray nozzle 52 of the fluid spray system 110.In this manner, only one spray nozzle 52 of the fluid spray system 110is operational at any one time. This configuration serves to minimizetemporary blockage as a result of condensate 36 being temporarilytrapped within the filter material. This configuration also serves tomaximize fluid pressure from the fluid pump 50. Accordingly,substantially all of the suction 260 or fluid pressure generated by thepump 50 during the cleaning phase 60 can direct and force the fluidspray 112 through the diverter valve 58 in one of the cleaning phasepositions 150 and through a single spray nozzle 52. Accordingly, thesprayed condensate 142 from each spray nozzle 52 can have a maximumamount of fluid pressure for projecting the sprayed condensate 142, inthe form of the fluid spray 112, toward the respective portion of theinternal lint filter 54.

After the cleaning phase 60 of the spray sequence 160 is completed forthe fluid spray system 110, lint particles 64 and sprayed condensate 142are contained within the drain channel 38. The amount of lint particles64 contained within the drain channel 38 can vary depending upon certainfactors. Such factors include, but are not limited to, the number oftimes a particular cleaning phase 60 or spray sequence 160 is performed,the type of drying function 30 performed, the amount of lint particles64 captured by each internal lint filter 54, and other similar factors.

The spray sequence 160 can include a single operation of each spraynozzle 52 for the internal lint filter 54. Where multiple lint screens100 are included within the internal lint filter 54, various spraysequences 160 can be conducted depending upon the amount of lintparticles 64 captured within the internal lint filter 54. By way ofexample, and not limitation, where the internal lint filter 54 mayinclude sequential first and second internal lint filters, the firstinternal lint filter may be adapted to capture greater amounts of linthaving a larger size of lint particles 64. The second internal lintfilter may capture smaller amounts of lint. Because the first internallint filter will typically capture more lint particles 64, a spraysequence 160 dedicated to this first internal lint filter may operatemore frequently than a separate spray sequence 160 for the secondinternal lint filter. The same may be true for additional lint screens100 of internal lint filters 54 for the lint removal system 90.

Where lint particles 64 and sprayed condensate 142 are contained withinthe drain channel 38, the pump 50 may be activated according to variousfactors for moving the lint particles 64 and sprayed condensate 142 tothe removable bottle 56. The pump 50 may be activated when a certainvolume of lint particles 64 and sprayed condensate 142 are containedwithin the drain channel 38 after each spray sequence 160 is completed,or activation of the pump 50 may be based upon the amount of spaceavailable within the removable bottle 56. A combination of theseinitiating events may be incorporated within the fluid spray system 110to remove the lint particles 64 and sprayed condensate 142 from thedrain channel 38 to the removable bottle 56.

As exemplified in FIGS. 10 and 11, the drain channel 38 can include anangled bottom 170 that defines a slope to use the force of gravity formoving sprayed condensate 142 and lint particles 64 from a front portion172 of the drain channel 38 proximate the internal lint filter 54 to arear portion 174 of the drain channel 38 proximate the fluid pump 50. Incertain aspects of the device, an additional spray nozzle 52 may beincluded at a front portion 172 of the drain channel 38 to assist inmoving the lint particles 64 and sprayed condensate 142 down the angledbottom 170 and toward the fluid pump 50. The activation of the first andsecond nozzles 116, 118 that serve the internal lint filter 54 can beconfigured to remove lint particles 64 from the front surface 114 of theinternal lint filter 54 and also assist in pushing the sprayedcondensate 142 and lint particles 64 down the angled bottom 170 andtoward the rear portion 174 of the drain channel 38. In such anembodiment, the front portion 172 of the drain channel 38 may include acurve or chamfer 176 that provides for a substantially laminar path thatcan assist in pushing the lint particles 64 and sprayed condensate 142toward the rear portion 174 of the drain channel 38. The rear portion174 of the drain channel 38 can include an angled back surface 178. Thisangled back surface 178 in conjunction with the angled bottom 170 drainchannel 38 provides for a single low point 180 proximate a back corner182 of the drain channel 38 where the fluid pump 50 is typicallylocated. Accordingly, the drain channel 38 is designed to allow the lintparticles 64 and sprayed condensate 142 to flow towards this low point180 of the drain channel 38 to be removed by the fluid pump 50.

When an initiating signal is provided to the drain pump 50, the drainpump 50 is activated and sprayed condensate 142 and lint particles 64are moved by the fluid pump 50 toward the diverter valve 58. Thediverter valve 58, during this portion of the spray sequence 160, ismoved to a drain phase 62 such that the lint particles 64 and sprayedcondensate 142 are moved through the diverter valve 58 and toward theremovable bottle 56. The removable bottle 56 is removable from theappliance 12 for pouring the lint particles 64 and sprayed condensate142 into an external drain or into a trash receptacle.

In certain embodiments, the removable bottle 56 can include an indicatorthat informs the user when the removable bottle 56 is full of lintparticles 64 and/or sprayed condensate 142 such that removal isnecessary. Accordingly, the removable bottle 56 can include varioussensors that can monitor the amount of lint particles 64 and/or sprayedcondensate 142 therein to provide this indicator to the user of theappliance 12. As discussed above, when the removable bottle 56 becomessufficiently full such that additional operation of the pump 50 anddiverter valve 58 in the drain phase 62 may cause an overflow of theremovable bottle 56, the appliance 12 may prevent operation of certaindrying functions 30 until such time as the removable bottle 56 isemptied.

After the drain phase 62 is complete, the diverter valve 58 can berepositioned to one of the cleaning phase positions 150 to perform thenext cleaning phase operation to spray condensate 36 onto the internallint filter 54 using one of the spray nozzles 52. The specific operationof the spray sequences 160 and operation of the diverter valve 58 willbe described more fully below.

As exemplified in FIGS. 8-13, the heat pump system 10 can include a heatexchange plate 190 that serves to support the evaporator 34 andcondenser 40 of the heat pump system 10. Typically, a front region 192of the heat exchange plate 190 serves to support the evaporator 34 and arear region 194 of the heat exchange plate 190 supports the condenser40. The heat exchange plate 190 can include sidewalls 196 that laterallysupport the evaporator 34 and condenser 40. The sidewalls 196 caninclude one or more shoulders 198 that can at least partially extendbetween the evaporator 34 and condenser 40 to provide consistent spacingand secure positioning in multiple directions for the evaporator 34 andcondenser 40.

The heat exchange plate 190 includes a base 202 that serves to separatethe airflow path 20 from the drain channel 38. This base 202 provides alateral dividing wall that defines the airflow path 20 above the base202 and the drain channel 38 below the base 202. Accordingly, as processair 24 or moisture-laden air 32 moves through the airflow path 20, theprocess air 24 moves over the base 202 of the heat exchange plate 190and through the evaporator 34 and condenser 40. The process air 24 issubstantially prevented from entering the drain channel 38 through theplacement of the base 202 of the heat exchange plate 190.

Referring again to FIGS. 8-13, the front region 192 of the heat exchangeplate 190 includes a sloped area 210 that serves to collect condensate36 that falls from the evaporator 34 during the performance of a dryingfunction 30. As this condensate 36 falls on the front region 192 of theheat exchange plate 190, the condensate 36 is directed through thesloped area 210 by a series of baffles 212 that are positioned at anangle with respect to the flow of process air 24 within the airflow path20. As the condensate 36 falls onto the sloped area 210, the condensate36 falls in typically small quantities. These small quantities ofcondensate 36 collect between the baffles 212. The condensate 36 flowsdown the sloped area 210 and through a meandering drain 214 that isdefined generally below a top edge 216 of each of the baffles 212. Thesebaffles 212 and the meandering drain 214 serve to block the process air24 such that the movement of process air 24 does not push the condensate36 up the sloped area 210 toward the rear region 194 and the condenser40. Because the baffles 212 are positioned at an angle along the slopedarea 210, the condensate 36 can flow along a directing surface 218 ofthe baffles 212 and within the meandering drain 214.

The condensate 36 is directed along the sloped area 210 and toward acondensate drain 230 positioned proximate a filter seat 232 of the heatexchange plate 190. The filter seat 232 receives a bottom portion 234 ofthe internal lint filter 54 and secures the internal lint filter 54thereto to prevent inadvertent removal of the internal lint filter 54during operation of the drying appliance 12. The condensate drain 230 istypically positioned immediately behind or downstream of the filter seat232 such that condensate 36 moving down the sloped area 210 and betweenthe baffles 212 of the heat exchange plate 190 can drop into the drainchannel 38 behind the internal lint filter 54. The bottom portion 234 ofthe internal lint filter 54 can also serve to block a portion of theprocess air 24 from pushing the condensate 36 up the sloped area 210 andtoward the condenser 40.

As exemplified in FIGS. 8-13, the baffles 212 within the front portion172 of the heat exchange plate 190 are typically oriented in a diagonalconfiguration. These baffles 212 can be disposed in a similar angularconfiguration or can be disposed in various angles so long as thebaffles 212 serve to define the meandering drain 214 and at leastpartially block the movement of process air 24 within the baffles 212.In this manner, the condensate 36 can drain down the sloped area 210 ofthe heat exchange plate 190 to the condensate drain 230.

The condensate drain 230 can be defined by a slot that extends betweenthe sloped area 210 of the heat exchange plate 190 and the filter seat232. This condensate drain 230 can also be in the form of a series ofapertures defined within the base 202 of the heat exchange plate 190. Toassist in supporting the internal lint filter 54, the filter seat 232can be supported at least partially by the sloped area 210 of the heatexchange plate 190 through one or more support structures 240 thatextend across or through the condensate drain 230. In this manner, theheat exchange plate 190 can support and fix the position of the internallint filter 54 as well as the evaporator 34 and condenser 40 for theheat pump system 10.

This unitary base 202 that forms part of the heat exchange plate 190 canminimize wobble, vibration, and other noise that may emanate from theevaporator 34, condenser 40, internal lint filter 54, spray nozzles 52or other component positioned within the basement 242 of the appliance12 during performance of a drying function 30. While the heat exchangeplate 190 includes the condensate drain 230 and opening 250, the drainchannel 38 can be at least as wide, if not wider, than the heat exchangeplate 190, such that condensate 36 that may flow outside of thecondensate drain 230 and/or the condensate opening 250 may still fallinto the drain channel 38 to be delivered to the fluid pump 50.

Referring again to FIGS. 8-13, in front of the filter seat 232, the heatexchange plate 190 defines a lint and condensate opening 250 throughwhich the lint particles 64 can be pushed by the sprayed condensate 142and into the drain channel 38. Through the condensate drain 230 and thelint and condensate opening 250, all of the condensate 36 and lintparticles 64 and sprayed condensate 142 are moved into the common drainchannel 38 for removal through a single fluid pump 50. The inclusion ofa single fluid pump 50 and a single diverter valve 58 for removingcondensate 36 as well as lint particles 64 and sprayed condensate 142through the appliance 12 minimizes the amount of motors 270 andoperational components needed for moving the material through theappliance 12.

The base 202 of the heat exchange plate 190 serves to position theevaporator 34 and a condenser 40 within the airflow path 20. The heatexchange plate 190 also elevates the evaporator 34 and the condenser 40over the drain channel 38. Accordingly, the drain channel 38 can beplaced at a low elevation within the basement 242 of the appliance 12 toefficiently capture condensate 36, lint particles 64 and sprayedcondensate 142 while minimizing the amount of space necessary within thebasement 242 for accomplishing these functions. The sidewalls 196 of theheat exchange plate 190 also define the sides of the airflow path 20that serve to direct the movement of process air 24 and moisture-ladenprocess air 24 through the airflow path 20 and through the heat pumpsystem 10 of the appliance 12. This efficient movement of process air 24through the heat exchange plate 190 also provides for an efficientthermal transmission of heat between the evaporator 34, the condenser40, the process air 24, and heat exchange material contained within theheat pump system 10.

Referring now to FIGS. 20-23, the diverter valve 58 that apportionscondensate 36 from the pump 50 between the first and second nozzles 116,118 to define the cleaning phase 60 can include multiple separatecleaning phase positions 150 for sequentially delivering condensate 36from the drain channel 38 to a first nozzle 116 for serving a firstportion 126 of the internal lint filter 54 and then to a second nozzle118 for serving a second portion 128 of the internal lint filter 54.During this cleaning phase 60, the first and second nozzles 116, 118project the condensate 36 pumped by the fluid pump 50 onto a surface ofthe internal lint filter 54 to direct the captured lint particles 64 andsprayed condensate 142 to the drain channel 38.

The condensate 36 that is sprayed during the cleaning phase 60 istypically free of or substantially free of lint particles 64. These lintparticles 64 are typically removed during a previous drain phase 62 ofthe diverter valve 58. During operation of the appliance 12 some minimalamounts of lint particles 64 may be present within the condensate 36sprayed through the first and second nozzles 116, 118. These minimallint particles 64 will typically be able to flow freely through thespray nozzles 52. In various aspects, fluid from an external fluidsource, such as a faucet, may be used to supplement the condensate 36.The external fluid may also be used instead of condensate 36 in certainaspects of the device.

As discussed above, after the cleaning phase 60 is complete, the drainchannel 38 contains both washed lint particles 64 and sprayed condensate142 therein. This material is then moved toward the location of the pump50, through at least the force of gravity to the low point 180 proximatethe fluid pump 50. Activation of the fluid pump 50 causes a suction 260within the drain channel 38 to remove the lint particles 64 and sprayedcondensate 142 through the fluid pump 50 and toward the diverter valve58. Before the lint particles 64 and sprayed condensate 142 from thefluid pump 50 reaches the diverter valve 58, the diverter valve 58 ismanipulated to define a drain position corresponding to the drain phase62. In this manner, the lint particles 64 and sprayed condensate 142 aremoved through the diverter valve 58 in the drain phase 62 for movementof the lint particles 64 and sprayed condensate 142 to the removablebottle 56.

Referring again to FIGS. 20-23, the diverter valve 58 can include adedicated motor 270 that is attached to a rotating disk 272 within amixing chamber 274 of the diverter valve 58 via a shaft 276. Theposition of the disk 272 is detected by a sensing mechanism 278, such asa reed switch, Hall sensor, or other similar sensing mechanism 278 thatactivates and deactivates the motor 270 based upon the position of thedisk 272 within the mixing chamber 274. When a particular position ofthe disk 272 is required to define one of the cleaning phase positions150 or the position of the drain phase 62, the motor 270 can beactivated. The sensing mechanism 278 proximate the motor 270 detectswhen the disk 272 or a valve opening 282 in the disk 272 is at theappropriate position and deactivates the motor 270 such that the disk272 is maintained at the appropriate position. Accordingly, only oneoutlet 280 is adapted to receive either condensate 36 or lint particles64 and sprayed condensate 142 for removal through the diverter valve 58.Accordingly, the diverter valve 58 can be used to specifically directthe movement of material through the diverter valve 58 to appropriatepositions within the appliance 12. As a consequence, the diverter valve58 can also segregate material within the appliance 12 so that it iskept away from certain portions of the appliance 12, such as keepinglint particles 64 away from the spray nozzles 52.

Referring again to FIGS. 20-23, the diverter valve 58 can include asingle inlet 290 that receives material from the fluid pump 50. Theinlet 290 delivers this material into the mixing chamber 274 to bedelivered through the valve opening 282 and to only one outlet 280 of aplurality of outlets 280 of the diverter valve 58. The plurality ofoutlets 280 include a first nozzle outlet 292 and a second nozzle outlet294 that correspond to the cleaning phase 60 and a bottle outlet 296that corresponds to the drain phase 62. As discussed previously, theinternal disk 272 is rotated about the shaft 276 such that the valveopening 282 in the disk 272 allows for fluid to pass from the mixingchamber 274 through only one of the outlets 280. Each outlet 280corresponds to one spray nozzle 52, such as in the case of a cleaningphase 60, or a path to the water bottle 56, in the case of the drainphase 62. Where additional spray nozzles 52 beyond the first and secondnozzle 116, 118 are included, additional cleaning phase positions 150can be included within the diverter valve 58 to account for each spraynozzle 52 within the fluid spray system 110. In various aspects of thedevice, where multiple lint screens 100 are included, the diverter valve58 described herein can define a primary diverter valve 58 and secondarydiverter valves can be positioned downstream for serving the spraynozzles 52 of a particular internal lint filter 54.

As exemplified in FIGS. 20-23, the mixing chamber 274 and disk 272 areconfigured such that the drain phase 62 defines a smooth andsubstantially laminar fluid path to limit the ability of lint particles64 to clog the diverter valve 58 during use. Accordingly, theconfiguration of the mixing chamber 274 is free of or is substantiallyfree of accumulation points of fluid that may capture and retain lintparticles 64 during use.

As exemplified in FIGS. 18-23, the pump 50 and diverter valve 58 canwork in conjunction with one another to perform various spray sequences160 for moving condensate 36 and lint particles 64 through the appliance12. These spray sequences 160 can include various active and idle statesor sequences that can be incorporated sequentially for removing lintparticles 64 from the internal lint filter 54 and also for movingcollected lint particles 64 and sprayed condensate 142 from the drainchannel 38 to the water bottle 56. After a drying function 30 of theappliance 12 is initiated, process air 24 moves through the damparticles 16 within the drum 14 and defines moisture-laden air 32 that ismoved through the lint removal system 90 and into the evaporator 34.Condensate 36 is precipitated from the moisture-laden air 32 and iscollected within the drain channel 38, as described in the variousaspects of the device included above.

Referring now to FIGS. 18 and 19, a method 800 for operating anexemplary spray sequence 160 is disclosed. According to the method 800,a drying function 30 is performed to collect condensate 36 in the drainchannel 38 and to clean lint particles 64 from the moisture-laden air 32(step 802). Before operating one of the spray sequences 160 using thecollected condensate 36 within the drain channel 38, a sensor or monitorwithin the drain channel 38 determines the amount of condensate 36within the drain channel 38 (step 804). Only when a sufficient amount ofcondensate 36 is collected therein is the spray sequence 160 activated.Until such time as this amount of condensate 36 is collected, the heatpump system 10 continues to deliver condensate 36 to the drain channel38 and the pump 50 will typically remain idle (step 806). Once theappropriate amount of condensate 36 is contained within the drainchannel 38, the diverter valve 58 is moved to a first cleaning phaseposition 150 that corresponds to the first spray nozzle 52 (step 808).Typically, lint particles 64 from a previous spray sequence 160 has beenmoved to the water bottle 56 such that all or substantially all of thelint particles 64 from the previous spray sequence 160 has been removedand only captured condensate 36 remains within the drain channel 38.

During the cleaning phase 60, the pump 50 is activated and condensate 36from the drain channel 38 is moved through the diverter valve 58 in thefirst cleaning phase position 150 and is moved through the first spraynozzle 52 (step 810). The pump 50 is activated for a predetermined timeto clean the front surface 114 of a first portion 126 of the internallint filter 54. The time period of this first active sequence 310 canvary in length of time. By way of example, and not limitation, the firstactive sequence 310 can be for a period of approximately 15 seconds.After completion of the first active sequence 310, a first idle sequence312 is initiated where a pump 50 is deactivated and the flow ofcondensate 36 to the first nozzle 116 is substantially stopped (step812). This idle sequence 312 can last for various lengths of time. Thisidle sequence 312 can allow time for the fluid sprayed during the firstactive sequence 310 to soak into various portions of the lint particles64 and make the lint particles 64 heavier and easier to move during asubsequent active sequence.

After completion of the first idle sequence 312, which may last fromapproximately two seconds to approximately 10 seconds, and typicallyapproximately five seconds, a second active sequence 314 is activatedwith respect to the first nozzle 116. Accordingly, the pump 50 isreactivated to initiate the second active sequence 314 and condensate 36is moved from the drain channel 38, through the first nozzle 116, andonto the first portion 126 of the internal lint filter 54 (step 814).This second active sequence 314 can last for a predetermined amount oftime. Such time can be in the range of from approximately five secondsto approximately 20 seconds. Typically, the time period of the secondactive sequence 314 will be substantially similar to that of the timeperiod for the first active sequence 310. After the second activesequence 314 is complete, the pump 50 is deactivated and the flow of thecondensate 36 to the first spray nozzle 52 is substantially stopped(step 816).

Through this sequence of the first active sequence 310, idle sequence312 and second active sequence 314, substantially all of the lintparticles 64 captured on the front surface 114 of the internal lintfilter 54 are typically removed and pushed toward or into the drainchannel 38. The pump 50 remains deactivated for a certain amount of timeto allow for trapped condensate 120 that may be entrapped within thefirst portion 126 of the internal lint filter 54 to become dislodged,evaporate, or otherwise be removed from the filter material of the firstportion 126 of the internal lint filter 54.

Referring again to FIGS. 18-23, after the cleaning phase 60 is completewith respect to the first portion 126 of the internal lint filter 54,the diverter valve 58 operates to move the disk 272 to the secondcleaning phase position 150 that corresponds to the second spray nozzle52 (step 818). Once in this position, the pump 50 is again activated todefine the first active sequence 310 to move condensate 36 through thediverter valve 58 and into the second spray nozzle 52 for cleaning thesecond portion 128 of the internal lint filter 54 (step 810). After thefirst active sequence 310 is complete with respect to the second portion128 of the internal lint filter 54, the idle sequence 312 is initiatedand the pump 50 is deactivated (step 812). After the predetermined timeis complete, the pump 50 is reactivated to initiate the second activesequence 314 to complete the cleaning of the second portion 128 of theinternal lint filter 54 by moving condensate 36 through the second spraynozzle 52 (step 814). After the spray sequence 160 is complete withrespect to the second portion 128 of the internal lint filter 54 (step820), the diverter valve 58 is then moved to the drain phase 62 position(step 822). As discussed above, in this position, lint particles 64 andsprayed condensate 142 are contained within the drain channel 38 and aremoved via the fluid pump 50 through the diverter valve 58 in theposition corresponding to the drain phase 62 and up to the removablebottle 56 typically positioned at a top portion 436 of the appliance 12(step 824). In the drain phase 62, the pump 50 may be activated throughvarious active phases and intermittent idle phases to move the lintparticles 64 and sprayed condensate 142 into position for being removedfrom the drain channel 38 by the fluid pump 50. Typically, the drainphase 62 may be a single operation of the pump 50 for a predeterminedperiod of time. This period of time may be within a range of fromapproximately 20 seconds to approximately 60 seconds and typically willlast approximately 30 seconds.

The exemplary spray sequence 160 identified above in method 800 can bemodified based upon the particular drying function 30 being performed bythe laundry appliance 12. By way of example, and not limitation, a toweldrying function may collect more lint particles 64 than a delicatesdrying function. Accordingly, the time periods for the spray sequence160 may be adjusted based upon a particular drying function 30 beingperformed. Additionally, where greater amounts of lint particles 64 maybe captured within the internal lint filter 54, a spray sequence 160corresponding to the first and second nozzles 116, 118 and the bottle 56may include additional active sequences that are separated by additionalidle sequences 312 such that three or more active sequences may beseparated by corresponding idle sequences 312. Various lint monitors canalso be included proximate the internal lint filter 54 to monitorwhether lint particles 64 have been fully removed from the front surface114 of the internal lint filter 54 or from the drain channel 38. Where agreater amount of lint particles 64 may require additional activesequences, the lint monitor may recognize that lint particles 64 remainon a portion of the internal lint filter 54 and may automaticallyoverride a predetermined sequence to reinitiate an additional activesequence to spray a surface of the internal lint filter 54 an additionaltime. Such monitors can include, but are not limited to, airflowmonitors, visual monitors, weight sensors, lasers, sensors that monitoran efficiency level of a compressor for the heat pump system 10,combinations thereof, and other similar sensors that may be used tomonitor an amount of lint particles 64 entrapped in a surface of theinternal lint filter 54.

As exemplified in FIGS. 9-11 and 14-17, the internal lint filter 54 caninclude first and second spray nozzles 116, 118 that are adapted tospray condensate 36 onto respective first and second portions 126, 128of the internal lint filter 54. Each spray nozzle 52 can include acentrally positioned fluid inlet 320 that is defined within anattachment surface 322 of the spray nozzle 52. Within the fluid inlet320, a substantially planar surface 324 extends through the fluid inlet320 and empties into a wide and multi-faceted deflecting surface 326that includes two diverging lateral faces 328. These diverging lateralfaces 328 are connected by an expanding curved fluid deflecting face330. The fluid deflecting face 330 and the planar surface 324 define asubstantially continuous and laminar flow path 332 through the spraynozzle 52. The deflecting face 330 is positioned at an angle withrespect to the fluid inlet 320 of the spray nozzle 52 to produce agenerally flat fluid spray 112 that can be directed toward a surface ofthe internal lint filter 54. The internal lint filter 54 can includeadditional portions other than the first and second portions 126, 128such that the internal lint filter 54 may be divided into three or moresections. These sections can be defined by interior frame members of theinternal lint filter 54 that add structural rigidity to the internallint filter 54 and resist deflection due to the flow of process air 24and fluid spray 112 during operation of the appliance 12. These variousdivided portions of the internal lint filter 54 can be sprayed bydedicated spray nozzles 52 wherein each divided portion of the internallint filter 54 is served by a dedicated spray nozzle 52. The variousdivided portions may also be served by the first and second nozzles 116,118. In such an embodiment, the frame members may be located at the backsurface 140 of the internal lint filter 54. In this manner, these framemembers may be positioned to be free of interference with the operationof the fluid spray 112 projecting from the first and second nozzles 116,118 onto the two or more divided portions of the internal lint filter54.

The fluid deflecting face 330 and the diverging lateral faces 328 areadapted to produce a flat and laminar spray that is positioned at anangle with respect to the internal lint filter 54. This angle can bevarious angles from parallel with the internal lint filter 54 or can beangled with respect to the internal lint filter 54. One such angle canbe approximately 150° from horizontal or approximately 60° into thesurface of the internal lint filter 54. As discussed above, the spraynozzles 52 can be directed to spray fluid through the laminar flow path332 and onto a front or back surface 114, 140 of the rear filter. Incertain aspects of the device, both the front and back surfaces 114, 140of the internal lint filter 54 may be sprayed. The path of the fluidbeing sprayed from the first and second nozzles 116, 118 can takevarious shapes. These shapes can include, but are not limited to,fan-shaped, conical, arcuate, combinations thereof, and other shapesthat are adapted to push the lint particles 64 off from the frontsurface 114 of the internal lint filter 54 toward the drain channel 38.

The first and second nozzles 116, 118 can include the fluid inlet 320that extends from an attachment surface 322 of each spray nozzle 52. Theattachment surface 322 of the spray nozzle 52 can include a concentricsealing geometry 340 that extends outward from the inlet 290. Thisconcentric sealing geometry 340 is integral with the attachment surface322 and provides a self-sealing attachment. Accordingly, no separatesealing member is typically disposed between the inlet 290 of each spraynozzle 52 and the sidewall 196 to which it is attached or at the tube342 through which the condensate 36 is delivered to the first and secondnozzles 116, 118. Each spray nozzle 52 can be attached to a sidewall 196of the airflow path 20 such that the first and second spray nozzles 116,118 can be in a fixed position relative to the internal lint filter 54.Threaded receptacles 344 that are integral with the first and secondnozzles 116, 118 can receive fasteners for attaching the attachmentsurface 322 of each spray nozzle 52 to an interior surface 346 of thesidewall 196 airflow path 20.

Referring again to FIGS. 14-17, the fluid inlet 320 can be defined by asubstantially consistent opening 76 that extends through the inlet 290and to the deflecting surface 326. At least one narrowed portion 350 ofthe inlet 290 can be included. This narrowed portion 350 serves to atleast partially increase the pressure of the condensate 36 beingprojected from the first and second spray nozzles 52. This narrowedportion 350 can be a rib 352 that extends around a portion of the fluidinlet 320. The narrowed portion 350 can also be a generally conicalshape of fluid inlet 320 that gradually narrows toward the deflectingsurface 326 for gradually increasing the pressure of the condensate 36being moved through the first and second spray nozzles 52. Where anarrowed portion 350 is included, the planar surface 324 extendingthrough the inlet 290 is typically not interrupted by the narrowedportion 350. Accordingly, the planar surface 324 can extend through thenarrowed portion 350 to maintain the laminar flow path 332 through theentire fluid inlet 320 and toward the fluid deflecting face 330.

Referring now to FIGS. 1-24, having described various aspects of thefluid spray system 110 and the lint removal system 90, a method 900 isdisclosed for operating the laundry appliance 12 having the fluid spraysystem 110 and the lint removal system 90. According to the method 900,a drying function 30 is activated (step 902). During performance of thedrying function 30, damp or wet articles 16 contained within the drum 14are dried by passing process air 24 through the drum 14. This processair 24 captures moisture from the damp articles 16. This moisturedefines moisture-laden air 32 that is then moved toward the lint removalsystem 90 (step 904). The moisture-laden air 32 is then moved through afirst removable lint filter 72 (step 906). Within the removable lintfilter 72, larger lint particles 64 are typically captured.Additionally, the largest amount of lint particles 64 are typicallycaptured within the removable lint filter 72 that is positioned at theopening 76 for the door 74 of the laundry appliance 12. Themoisture-laden air 32 is then moved further down the airflow path 20toward the internal lint filter 54. The moisture-laden air 32 is thenmoved through the internal lint filter 54 to remove additional lintparticles 64 (step 908). After passing through the internal lint filter54, very little, if any, lint particles 64 remain within themoisture-laden air 32. These lint particles 64 are entrapped within theremovable lint filter 72 and the internal lint filter 54.

According to the method 900, the moisture-laden air 32 is then movedthrough the evaporator 34 of the heat pump system 10 (step 910). Theevaporator 34 reduces the temperature of the moisture-laden air 32 todehumidify and precipitate condensate 36 from the moisture-laden air 32(step 912). This condensate 36 then falls onto a base 202 of the heatexchange plate 190 and is moved through the baffles 212 of the slopedportion toward the drain channel 38 (step 914). This condensate 36 isthen captured within the drain channel 38 and is moved down the slope ofthe angled bottom 170 of the drain channel 38 toward the fluid pump 50(step 916). Once a sufficient amount of condensate 36 is containedwithin the drain channel 38, the fluid spray system 110 is ready toinitiate a spray sequence 160 for cleaning the internal lint filter 54at the predetermined time. This predetermined time for initiating thespray sequence 160 can be at any one of various occurrences. Suchoccurrences can include, but are not limited to, the ending of a dryingfunction 30, a certain time into a particular drying function 30, a timeat which a sensor monitoring the internal lint filter 54 senses that anappropriate amount of lint particles 64 are entrapped within theinternal lint filter 54, a reduced efficiency of a component of the heatpump system 10, such as a reduced efficiency of the compressor servingthe evaporator 34 and condenser 40, a reduced amount of heat exchangewithin the heat pump system 10, combinations thereof, and other similaroccurrences.

Referring again to FIGS. 1-24, at the appropriate time, the fluid pump50 is activated and the diverter valve 58 is moved to a cleaningposition. The fluid pump 50 then delivers the condensate 36 from thedrain channel 38 through the diverter valve 58 and to, sequentially, thefirst and second spray nozzles 52 (step 918). Through the spray sequence160, condensate 36 is sprayed through the first and second spray nozzles52 onto the first and second portions 126, 128 of the internal lintfilter 54, respectively, to push the lint particles 64 from the surfaceof the internal lint filter 54 into the drain channel 38 (step 920). Asdiscussed above, activation of the first and second nozzles 116, 118 canpush the lint particles 64 off the front surface 114 of the internallint filter 54 and can also assist in pushing the lint particles 64 downthe slope of the angled bottom 170 of the drain channel 38 toward thefluid pump 50. After completion of the cleaning phase 60 of the spraysequence 160, the diverter valve 58 is then moved to a drain phase 62and the fluid pump 50 is again activated to move the lint particles 64and sprayed condensate 142 from the drain channel 38, through thediverter valve 58 in the drain phase 62 and up to the removable waterbottle 56 (step 922).

Referring now to FIGS. 1, 2, 5-11 and 25-29, within a rear portion 174of the basement 242, a sump 410 is positioned downstream of the drainchannel 38. This sump 410 is adapted to receive condensate 36 from theheat exchangers 26. The sump 410 is also configured to receive the fluidspray 112 and lint particles 64 from the spray nozzles 52 in the form ofa fluid and lint mixture 412. This condensate 36 and the fluid and lintmixture 412 is then distributed from the sump 410 to various portions ofthe appliance 12. A sump pump 414 is disposed within a sump cover 416that at least partially seals the sump 410 so that condensate 36 and thefluid and lint mixture 412 can be pumped through a fluid outlet 418 ofthe sump cover 416 into a separate location of the appliance 12. Thissump cover 416 includes a plate member 430 having a perimeter seal 432that engages a cover seat 434 disposed at a top portion 436 of theperimeter walls 438 of the sump 410. At this location, the engagement ofthe sump cover 416 and the cover seat 434 seals the sump 410 to allowfor efficient operation of the sump pump 414. The sump cover 416 alsoincludes a cup 440 that connects with the plate member 430 and includesan enlarged pump inlet 442 for accommodating passage of the fluid andlint mixture 412 without clogging the sump pump 414. The cup 440 forms apump flow path 446 from the pump inlet 442, through an impeller chamber444 of the cup 440 and to the fluid outlet 418.

Referring again to FIGS. 27-29, the sump pump 414 including the impeller450 sits within the cup 440 such that the impeller 450 of the sump pump414 rotates within the impeller chamber 444 of the cup 440. Throughoperation of the impeller 450, condensate 36 and the fluid and lintmixture 412 can be moved from the sump 410 upward into the pump inlet442 positioned at a bottom of the cup 440 and through a fluid outlet 418defined within the sump cover 416. The cup 440 has a generally circularshape that allows for rotational operation of the impeller 450 toprovide for movement of the condensate 36 and the fluid and lint mixture412 through the fluid outlet 418 of the sump cover 416.

As exemplified in FIGS. 18-29, operation of the impeller 450 within thecup 440 of the sump cover 416 can deliver the condensate 36 and thefluid and lint mixture 412 to and through the diverter valve 58 fordelivery to various portions of the appliance 12. The diverter valve 58can be operated to move at least condensate 36 as well as the fluid andlint mixture 412 up to the removable bottle 56 positioned within anupper area of the appliance 12. As discussed previously, the sump pump414 can also be operated within the sump cover 416 to move condensate 36to various spray locations such as spray nozzles 52 (shown in FIGS. 2and 3) for cleaning lint particles 64 from air filters 70 disposedwithin the appliance 12 and also for cleaning other portions of theappliance 12, such as heat exchangers 26 and the like.

Referring again to FIGS. 25-29, in operation, the sump cover 416includes a fluid level sensor 460 that is typically integrated withinthe plate member 430 of the sump cover 416. In at least one aspect ofthe device, the fluid level sensor 460 can include a pair of sensorcontacts 462 that are installed within the plate member 430 of the sumpcover 416. The fluid level sensor 460 delivers a signal when the levelof the condensate 36 and/or fluid and lint mixture 412 within the sump410 reaches at least one of the sensor contacts 462. The sensor contacts462 then deliver a signal to activate and potentially deactivate thesump pump 414. These sensor contacts 462 can project downward into thesump 410 at different elevations. A lower contact 464 can be used toactivate the sump pump 414 when the condensate 36 and the fluid and lintmixture 412 come into contact with this lower contact 464. An uppercontact 466 can be used as a shut-off contact when the removable bottle56 needs to be emptied, as will be more fully described below. Whenactivated, the sump pump 414 operates the impeller 450 to move materialwithin the sump 410 to the diverter valve 58 and onto various portionsof an appliance 12.

The sensor contacts 462 can be injection molded within a portion of thesump cover 416. The sensor contacts 462 can also be attached as separatemembers to a portion of the sump cover 416 for operation of the fluidlevel sensor 460. While a pair of metal plates or metal contacts areshown as the sensor contacts 462, additional fluid sensing mechanismscan be incorporated within the sump cover 416 for detecting the amountof material within the sump 410 and activating and deactivating the sumppump 414 at the appropriate time to remove material from the sump 410.

As exemplified in FIGS. 5-8 and 25-29, the sump cover 416 can alsoinclude an overflow port 470 that receives an overflow conduit 472 thatextends from the removable bottle 56 to the sump cover 416. Duringoperation of the appliance 12, the removable bottle 56 will fill withmaterial that includes condensate 36 and the fluid and lint mixture 412.It is necessary to remove this material periodically. If this materialis not removed on a regular basis, the material will tend to overflowout of the removable bottle 56. To prevent this overflow, the overflowconduit 472 is attached to a portion of a removable bottle 56 andextends down to the overflow port 470 defined within the sump cover 416.During operation of the appliance 12, as the removable bottle 56 reachesits full capacity of material, the overflow conduit 472 will direct thisoverflow of material back down to the sump 410 via the overflow port 470of the sump cover 416.

In certain conditions, where the removable bottle 56 remains at capacityand the appliance 12 continues to be operated, ultimately, the sump pump414 may direct a sufficient amount of condensate 36 and the fluid andlint mixture 412 to fill both the removable bottle 56 and the sump 410.In this condition, both of the sensor contacts 462 of the fluid levelsensor 460 will be in contact with material in the sump 410. At thispoint, portions of the appliance 12, or the entire appliance 12, can bedeactivated until such time as the removable bottle 56 is removed fromthe appliance 12 and the material included therein is emptied. Invarious operating conditions, the entire appliance 12 can be shut downwhen both the removable bottle 56 and the sump 410 are filled tocapacity with material. The appliance 12 may also be operated in acondition where the heat pump system 10 is deactivated so that nocondensate 36 is added to the drain channel 38 or to the sump 410.

During operation of the appliance 12, the appliance 12 may also shutdown when the sump pump 414 runs continuously and substantiallyuninterrupted for a certain amount of time. This condition will beactivated where the sump 410 is at or near its maximum capacity and aremovable bottle 56 is filled to a level where material is continuallybeing moved to the overflow conduit 472 and returned to the sump 410 viathe overflow port 470. This condition forms a feedback loop that mayresult in the deactivation of the appliance 12 until such time as theremovable bottle 56 is emptied of the material contained therein. Again,this material typically includes condensate 36 and/or the fluid and lintmixture 412.

Referring again to FIGS. 25-29, the sump cover 416 can include aperimeter seal 432 that directly engages the perimeter walls 438 of thesump 410. This perimeter seal 432 defines a sealed engagement, such thatsuction 260 generated by the sump pump 414 can be efficiently movedthrough the pump inlet 442 rather than suction 260 being lost at theperimeter walls 438 of the sump 410. Additionally, the cup 440 of thesump cover 416 can define a sealing engagement between the sump pump 414and the sump cover 416. Accordingly, operation of the impeller 450 ofthe sump pump 414 can generate sufficient suction 260 for movingcondensate 36 as well as the fluid and lint mixture 412 from the sump410 and to the diverter valve 58 to be delivered to various portions ofthe appliance 12.

Referring again to FIGS. 4-6 and 27-29, the overflow port 470 can bepositioned through a bottom portion 480 of a plate member 430 from thesump cover 416. In this manner, the bottom edge 482 of the overflow port470 is positioned below the lower contact 464 of the water level sensor.Accordingly, the bottom edge 482 of the overflow port 470 will typicallybe positioned below the level of material within the sump 410 when thesump 410 is activated. In this manner, when the level of the condensate36 and/or the fluid and lint mixture 412 reaches the lower contact 464of the fluid level sensor 460, the sump pump 414 is activated and thebottom edge 482 of the overflow port 470 is positioned below the levelof this material. Accordingly, when suction 260 is generated by the sumppump 414, the suction 260 can direct the material through the pump inlet442 at the bottom portion 480 of the cup 440 of the sump cover 416.Through this configuration, the suction 260 is not lost through theoverflow port 470. Accordingly, the bottom edge 482 of the overflow port470 is typically positioned below the water level during operation ofthe sump pump 414 so that air cannot pass into the overflow port 470 tocreate a condition where suction 260 from the sump pump 414 is lost andthe system is made less efficient.

Typically, as exemplified in FIGS. 5-8 and 25-29, the overflow conduit472 from the removable bottle 56 that extends to the overflow port 470of the sump cover 416 is a direct run of conduit that does not passthrough any check valve or other similar diverting mechanism. In thismanner, overflow material 490 from the removable bottle 56 can be fed bygravity through the overflow conduit 472 and into the sump 410 via theoverflow port 470. Typically, the overflow inlet 492 for the overflowconduit 472 is positioned in engagement with the removable bottle 56 ata higher location of the removable bottle 56. Through thisconfiguration, solid material such as lint particles 64 can settle tothe bottom of the removable bottle 56 so that primarily fluid is movedthrough the overflow conduit 472. By moving primarily fluid through theoverflow conduit 472, clogging as a result of lint particles 64 can beminimized so that the overflow conduit 472 and the overflow port 470 ofthe sump cover 416 can remain substantially unobstructed.

Referring again to FIGS. 27-29, in forming the sump cover 416, the cup440 that forms the pump inlet 442 for the sump cover 416 can be made asa separate piece that is subsequently attached to the remainder of thesump cover 416. By forming the cup 440 having the pump inlet 442 as aseparate piece, the impeller chamber 444 formed by the cup 440 caninclude a larger pump inlet 442. This larger pump inlet 442 provides formovement of lint particles 64 as well as fluid through the pump inlet442, past the impeller 450, and through a fluid outlet 418 to bedirected to the diverter valve 58 for the appliance 12. The cup 440 thatforms the pump inlet 442 also includes an enlarged portion 452 thatextends from the impeller chamber 444 and toward the outlet aperture 454of the fluid outlet 418. This enlarged portion 452 also allows formovement of the lint particles 64 and fluid through the fluid outlet418, past the impeller 450, and into the fluid outlet 418, withoutsubstantially clogging the sump cover 416 with the lint particles 64.The sump cover 416 can be made of various materials that can include,but are not limited to, plastic, metals, composite materials, variouspolymers, combinations thereof, and other similar materials.

In various aspects of the device, the appliance 12 can include a pair offluid outlets 418 that are utilized through bi-directional operation ofthe sump pump 414. In such an embodiment, clockwise rotation of theimpeller 450 can move material to a first fluid outlet 418. Conversely,counter-clockwise rotation of the impeller 450 can move the material toa second fluid outlet 418 for delivery to a separate location of theappliance 12.

Referring again to FIGS. 25-29, the sump cover 416 can include integralportions that are each formed within various portions of the sump cover416. By way of example, and not limitation, each of the pump inlet 442,fluid outlet 418, overflow port 470, pump seat 494, perimeter seal 432and fluid level sensor 460 can each be incorporated within portions ofthe sump cover 416. It is contemplated that some or all of thesefeatures can be injection molded within various portions of the sumpcover 416 to define a unitary assembly that can be attached as a singleunit onto the cover seat 434 defined at the perimeter wall 438 of thesump 410 to define a sealed connection between the sump cover 416 andthe sump 410 defined within the basement 242 of the appliance 12.Additionally, the pump seat 494 defined within the sump cover 416 candefine a specific seat within which the sump pump 414 can be disposedand secured. Accordingly, the sump pump 414 and sump cover 416 can bemanufactured at a single assembly, and attached over the sump 410.During manufacture, an electrical connection can be made between thesump pump 414 and the electrical system of the appliance 12, so that thesump pump 414 and sump cover 416 can be installed as a single assemblywithin the basement 242 of the appliance 12. By installing this singleassembly, the integral features of the sump cover 416 that can includethe fluid inlet 320, fluid outlet 418, overflow port 470, fluid levelsensor 460, impeller chamber 444, pump seat 494, and other features canbe integrally formed within this single assembly and installed as asingle unit within the basement 242 of the appliance 12. This can savetime and resources during manufacture, maintenance and repair, as thesump cover 416 and its component parts can be manufactured separatelyand installed as a single piece within the basement 242 of the appliance12.

Referring now to FIGS. 30-41, a lint filter 510, and, in variousembodiments, a fixed and substantially non-removable lint filter, can bedisposed within the airflow path 20 upstream of the heat exchangers 26.In this position, the lint filter 510 can be disposed within a filterreceptacle 512 defined within the inside surface 514 of the airflow path20. Accordingly, various securing features 516 are defined within theairflow path 20 for maintaining a position of the lint filter 510 in asecured and fixed position upstream of the heat exchanger 26.

As exemplified in FIGS. 31-36, the lint filter 510 can include acontinuous outer blocking flange 518 that extends outward from a topside 520 and opposing vertical sides 522 of the lint filter 510. Thecontinuous blocking flange 518 serves to secure the lint filter 510within the airflow path 20. The blocking flange 518 also preventsprocess air 24 from escaping around the lint filter 510. As process air24 moves toward the lint filter 510, the continuous blocking flange 518,through its engagement with the airflow path 20, at the filterreceptacle 512, creates a seal 524 that prevents leakage of process air24 around the outer frame 542 of the lint filter 510. In this manner,the process air 24, which is typically laden with lint particles 64, isfunneled through the filtering material 526 of the lint filter 510.Accordingly, substantial amounts of lint particles 64 can be capturedwithin the lint filter 510 during operation of the appliance 12.

Referring again to FIGS. 30-41, as process air 24 is moved from the drum14 (shown in FIG. 2) and toward the heat exchangers 26, the process air24 is moved through an upstream surface 540 or front side of the lintfilter 510. By securing the lint filter 510 within the filter receptacle512, vibration, wobbling, and other movement that might generate noiseresulting from the passage of process air 24 through the lint filter 510can be mitigated or substantially eliminated. To further resist thisvibration, the lint filter 510 can include the outer frame 542 thatextends around a perimeter 544 of the filtering material 526. One ormore internal frame members 546 can also extend within an interiorportion 548 of the lint filter 510. These internal frame members 546 canprovide additional strength and rigidity to the lint filter 510. Thisadditional rigidity serves to prevent vibration and other movement ofthe lint filter 510 and within the lint filter 510 during operation ofthe appliance 12.

According to various aspects of the device, the filtering material 526can be separated into filtering sections 560 that are separated by theinternal frame members 546. Accordingly, the filtering material 526 canbe included as three separate filtering sections 560 that extend betweenthe outer frame 542 and the internal frame members 546. Alternatively,the filtering material 526 can be a single piece of filtering material526 that extends within the frame of the lint filter 510. In such anembodiment, the internal frame members 546 are typically positionedagainst a downstream surface 562 of the filtering material 526. Byplacing the internal frame members 546 on the downstream surface 562 ofthe filtering material 526, the internal frame members 546 can opposedeflection of the filtering material 526 that may be experienced as theprocess air 24 moves through the upstream surface 540 of the filteringmaterial 526. The process air 24 may tend to bias the filtering material526 towards the heat exchangers 26. The placement of the internal framemembers 546 serves to oppose this tendency of the filtering material 526to move toward the heat exchangers 26 and limit vibration and othermovement within the lint filter 510.

As exemplified in FIGS. 37-41, the lint filter 510 can be positioned andsecured within the filter receptacle 512 within the airflow path 20. Theouter blocking flange 518 is typically not included within a bottom edge570 of the lint filter 510. This configuration makes the bottom edge 570of the frame for the lint filter 510 have a thinner profile that canseat within a bottom recess 572 of the filter receptacle 512 definedwithin a bottom wall 574 of the airflow path 20. Through this thinnerconfiguration, the bottom edge 570 of the lint filter 510 is disposed ata lower position with the inside surface 514 of the airflow path 20. Inthis manner, the filtering material 526 of the lint filter 510 extendsfrom near top edge 576 of the bottom recess 572 that is substantially atthe level of the inside surface 514 and extends upward through theairflow path 20. By seating the outer frame 542 of the lint filter 510within the bottom recess 572, the outer frame 542 can be positionedwithin the filter receptacle 512 so that a maximum amount of thefiltering material 526 of the lint filter 510 can be exposed forcapturing lint particles 64 as process air 24 moves through the airflowpath 20 and through the filtering material 526 of the lint filter 510.Additionally, because the blocking flange 518 of the lint filter 510 isnot contained within the bottom edge 570 of the lint filter 510, thelint filter 510 is able to sit lower within the airflow path 20 so thatthe bottom edge 570 of the lint filter 510 can be entirely orsubstantially seated within the bottom recess 572 of the filterreceptacle 512. By seating the bottom edge 570 of the outer frame 542within the bottom recess 572, this engagement also substantially forms aseal 524 at the bottom edge 570 of the lint filter 510 so that processair 24 is substantially unable to circumvent the lint filter 510. Theprocess air 24 is thereby directed through the filtering material 526 ofthe lint filter 510.

Referring again to FIGS. 32-41, the blocking flange 518 extends upwardalong the opposing vertical sides 522 of the lint filter 510. The filterreceptacle 512 defined within the airflow path 20 includes verticalwalls 590 that engage a forward surface 592 of the blocking flange 518.Similarly, the top area of the filter receptacle 512 includes a toprecess 594 that engages the forward surface 592 of the blocking flange518. To secure the forward surface 592 of the blocking flange 518against the vertical walls 590 and top recess 594 of the airflow path20, the filter receptacle 512 can include a plurality of tabs 596 thatengage a rearward surface 598 of the blocking flange 518. Accordingly,the blocking flange 518 is secured between the vertical walls 590 andtop recess 594 of the airflow path 20 on the forward side. The varioustabs 596 that extend at least along the top and bottom of the airflowpath 20 engage the rearward surface 598 of the lint filter 510.Accordingly, the forward and rearward surfaces 592, 598 of the lintfilter 510 are secured in the filter receptacle 512. This secureengagement that defines the filter receptacle 512 is configured tomaintain the lint filter 510 in a fixed position. The filter receptacle512 is further configured to minimize and/or substantially eliminatevibration experienced by the lint filter 510 within the lint filterreceptacle 512 during operation of the appliance 12.

Referring again to FIGS. 9-13, 39 and 41, the lint filter 510 can beseated within the filter seat 232 of the heat exchange plate 190. Thefilter seat 232 is typically configured to define the bottom recess 572of the lint filter receptacle 512. The various tabs 596 can be definedby the support structures 240 that extend across or through thecondensate drain 230 that is positioned downstream of the lint filter510. These support structures 240 can maintain the position of thefilter seat 232 and also secure the lint filter 510 within the filterseat 232 to minimize vibration or other movement. The support structures240 acting as the tabs 596 for the filter receptacle 512 also maintainthe positioning of the lint filter 510 in relation to the condensatedrain 230 downstream of the lint filter 510 and the condensate opening250 upstream of the lint filter 510. Through this configuration, themovement of condensate 36 and the fluid and lint mixture 412 can besubstantially unimpeded through the fixed positioning of the lint filter510 within the filter seat 232 and the filter receptacle 512 of theairflow path 20.

Referring again to FIGS. 9, 10, 18 and 37-40, the first and secondnozzles 116, 118 of the fluid spray system 110 can also define a portionof the filter receptacle 512. In such an embodiment, a body 610 of eachof the first and second nozzles 116, 118 can engage a front surface 612of the outer frame 542 for the lint filter 510. This engagement betweenthe first and second nozzles 116, 118 and the lint filter 510 serves tofurther secure the position of the lint filter 510. This configurationalso sets the positioning of the first and second nozzles 116, 118 inrelation to the filtering material 526 contained within the lint filter510. By fixing the position of the first and second spray nozzles 116,118 with respect to the lint filter 510, the spray sequence 160performed by the fluid spray system 110 can be maintained as asubstantially consistent fluid spray 112 that is directed to a surfaceof the filtering material 526 of the lint filter 510. Typically, thefirst and second nozzles 116, 118 direct the fluid spray 112 toward theupstream surface 540 of the lint filter 510. However, other sprayconfigurations can be implemented, such as spraying the fluid spray 112through the downstream surface 562 of the lint filter 510.

As exemplified in FIGS. 9, 10 and 37-40, the first and second nozzles116, 118, during operation of the particular spray sequence, direct aflow of fluid spray 112 onto a surface of the lint filter 510. Theinclusion of the internal frame members 546 serves to provide support tothe filtering material 526 and maintains the positioning of thefiltering material 526 during the spray sequence 160. During aparticular spray sequence 160, the force of the spray fluid 112emanating from the first and second nozzles 116, 118 may tend to push orotherwise bias the filtering material 526 toward the heat exchangers 26.By including the internal frame members 546 against a downstream surface562 of the filtering material 526, the position of the filteringmaterial 526 can remain substantially consistent over the life of theappliance 12. This consistent positioning of the filtering material 526also provides for a substantially consistent fluid spray 112 during aspray sequence 160 for effective removal of lint particles 64 from theupstream surface 540 of the filtering material 526.

While the term “non-removable” may be used to describe the nature of thelint filter 510, the term “non-removable” is used to describe the lintfilter 510 as being held in place and not removed for cleaning aftereach drying cycle. Rather, the lint filter 510 may be periodicallyremoved during service calls that are conducted by a serviceprofessional working on the appliance 12. Through the fixed location ofthe lint filter 510 within the lint filter receptacle 512, the lintfilter 510 can be removed from the lint filter receptacle 512 byremoving a portion of the airflow path 20 that defines the lint filterreceptacle 512. By way of example, and not limitation, a cover member620 of the airflow path 20 near the heat exchangers 26 for the airflowpath 20 may be removed and the lint filter 510 can be separated from thelint filter receptacle 512 for maintenance, repair, routine cleaning orreplacement.

Additionally, in various aspects of the device, the lint filter 510 canbe a removable-type lint filter that can be separated from the lintfilter receptacle 512 by a user of the appliance 12. In such anembodiment, this removal of the lint filter 510 may be accomplished byseparating various portions of the lint filter receptacle 512 so thatthe lint filter 510 can be removed from the airflow path 20. Typically,the lint filter 510 is substantially non-removable and is configured forperiodic removal from the airflow path 20 by a service professionalduring maintenance of the appliance 12.

Referring again to FIGS. 30-41, in order to fix the position of the lintfilter 510 within the filter receptacle 512, either the outer frame 542for the lint filter 510 or a portion of the lint filter receptacle 512can include an elastomeric member. This elastomeric member may act as adamper to absorb vibration or other movement that may be experienced bythe lint filter 510 during operation of the appliance 12. Such anelastomeric member can typically be made of a heat-resistant materialthat can withstand temperatures experienced within the airflow path 20during a particular drying operation.

Referring again to FIGS. 32-41, the lint filter 510 includes theblocking flange 518 that extends outward from a top side 520 and theopposing vertical sides 522 of the lint filter 510. As discussedpreviously, this blocking flange 518 is not included within the bottomedge 570 of the lint filter 510 so that the bottom edge 570 can seatlower within the lint filter receptacle 512 to maximize the amount ofthe filtering material 526 that extends across the airflow path 20 forcapturing lint particles 64 present within the process air 24 beingdirected from the drum 14 and to the heat exchangers 26.

According to various aspects of the device, the lint filter 510 caninclude a unitary plastic frame that includes the outer frame 542, thecontinuous blocking flange 518 and the internal frame members 546. Thefiltering material 526 can be attached to the perimeter frame and canextend across the internal frame members 546 as a single piece of afiltering material 526. It is also contemplated that the internal framemembers 546 can be separate members that are attached to the outer frame542. Additionally, the lint filter 510 can be made of various materialsthat can include, but are not limited to, plastic, metals, compositematerials, various polymers, combinations thereof, and other similarmaterials. The filtering material 526 can be made of various filteringmedia that can include, but is not limited to, metallic wire mesh,plastic wire mesh, a perforated member, fibrous filtering media, andother similar filtering material 526 that can capture lint particles 64and also be washed by the first and second nozzles 116, 118 throughoperation of the fluid spray system 110.

As exemplified in FIGS. 9, 10 and 31-41, the lint filter 510 isseparated into three filtering sections 560 through the inclusion of theinternal frame members 546. It is contemplated that the number of spraynozzles 52 included in the fluid spray system 110 can match the numberof filtering sections 560 within the lint filter 510. Accordingly, withthree filtering sections 560, three spray nozzles 52 may be included.Additionally, as exemplified in FIGS. 31 and 40, two spray nozzles 52can be used to spray fluid onto a plurality of filtering sections 560that may not match the number of spray nozzles 52 of the fluid spraysystem 110. The inclusion of the internal frame members 546, in certainrespects, supports the positioning of the filtering material 526 frombehind to prevent deflection or other displacement of the filteringmaterial 526 toward the heat exchanger 26. Such deflection ordisplacement may negatively affect the performance of the lint filter510 in capturing lint particles 64 and receiving the fluid spray 112from the first and second nozzles 116, 118 for cleaning lint particles64 off from the lint filter 510.

According to various aspects of the device, the lint filter 510 caninclude a plurality of filtering members that can be placed sequentiallywithin a position upstream of the heat exchanger 26. In such anembodiment, each filtering member may have its own dedicated set ofspray nozzles 52 for directing fluid to the respective filter member forcleaning lint particles 64 off from a surface of the particular filtermember. The number of filter members within the airflow path 20 caninclude a single filter member or a plurality of filter members. Thenumber of filter members can vary depending upon the design of theappliance 12 and the various performance parameters of the particularappliance 12.

According to various aspects of the device as exemplified in FIGS.37-39, the lint filter 510 can be disposed at an inclined angle 630 sothat a bottom edge 570 of the lint filter 510 is positioned closer tothe heat exchangers 26 and the top side 520 of the lint filter 510 ispositioned farther from the heat exchangers 26. In this manner, theupstream surface 540 of the lint filter 510 slopes away from the firstand second nozzles 116, 118. Because the upstream surface 540 of thelint filter 510 is positioned at an inclined angle 630, the fluid spray112 emanating from the first and second nozzles 116, 118 can moreefficiently direct the entrapped lint particles 64 down the upstreamsurface 540 of the lint filter 510 and through the condensate opening250. The inclined angle 630 also assists in preventing the entrappedlint particles 64 from stacking up at the bottom edge 570 of the lintfilter 510. Rather, the upstream surface 540 of the lint filter 510having the inclined angle 630 is conveniently suited to allow the lintparticles 64 to fall away from the upstream surface 540 and be directedinto the condensate opening 250 for removal into the drain channel 38for the appliance 12. In various aspects of the device, the inclinedangle 630 places a portion of the lint filter 510 over the condensateopening 250. By angling the upstream surface 540 of the lint filter 510,gravity assists in pulling the entrapped lint particles 64 away from theupstream surface 540 of the lint filter 510 and moving the lintparticles 64 toward the condensate opening 250 for removal.

Referring now to FIGS. 42-44, various aspects of the device can includea lint filter 510 that can be removed, typically, by a servicetechnician during a service call. For allowing convenient removal of thelint filter 510, the filter receptacle 512 that is defined within theinside surface 514 of the airflow path 20 can also include a filteraperture 640 disposed within one of the vertical walls 590 that definethe basement 242. The filter aperture 640 can allow for slidableengagement of the lint filter 510 into and out from the airflow path 20.The lint filter 510 can include a securing flange 642 that is positionedsubstantially perpendicular to the outer frame 542 for the lint filter510. This securing flange 642 can be used to secure the lint filter 510to the vertical wall 590 of the basement 242 at the filter aperture 640.Various fasteners 646 such as screws, clips, hasps, clasps, hooks, andother similar fixing mechanisms can be used to selectively secure thesecuring flange 642 of the lint filter 510 against the outer surface 644of the basement 242. This configuration allows the lint filter 510 to besecurely placed within the airflow path 20 such that the lint filter 510experiences a minimal amount of vibration, if any, during operation ofthe appliance 12.

As exemplified in FIG. 43, during a service call, the individualservicing the appliance 12 can remove the fasteners 646 from thesecuring flange 642 and can slidably remove the lint filter 510 from thefilter receptacle 512 and through the filter aperture 640 defined withinthe vertical wall 590 of the basement 242. To assist in securing thelint filter 510 to the vertical wall 590, a gasket 650, such as anelastomeric gasket, can be placed between the securing flange 642 of thelint filter 510 and the outer surface 644 of the vertical wall 590. Thisgasket 650 can be used to further secure the lint filter 510 within thefilter receptacle 512. The compression of the gasket 650 serves toabsorb at least a portion of the vibrations that may be experienced inthe basement 242, so that the lint filter 510 experiences a minimalamount of vibration during operation of the appliance 12. Thisconfiguration also serves to minimize the amount of noise that emanatesfrom the lint filter 510 during operation of the appliance 12.

Referring again to FIGS. 43 and 44, the lint filter 510 can include asupport portion 660 that extends between the securing flange 642 and theouter frame 542 extending around the filtering material 526 for the lintfilter 510. When the lint filter 510 is installed within the filterreceptacle 512, the support portion 660 extends between the verticalwall 590 and the airflow path 20 and allows for accurate positioning ofthe filtering material 526 within the airflow path 20. Accordingly,using the support portion 660 of the lint filter 510, substantially allof the filtering material 526 is placed within the airflow path 20.Various reinforcing ribs 662 can be placed within the support portion660. These reinforcing ribs 662 can also extend around portions of theouter frame 542 to reinforce the lint filter 510 and minimize vibrationof the outer frame 542 and the support portion 660 during operation ofthe appliance 12.

As exemplified in FIGS. 42-44, the filter receptacle 512 can be in theform of a slidably engageable slot within which the lint filter 510 canbe slidably operated between an installed position 670 and a removedposition 672. To slidably engage the filter receptacle 512, the blockingflange 518 of the lint filter 510 can be disposed along the top side 520and one of the vertical sides of the lint filter 510. As discussedpreviously, the blocking flange 518 along the top side 520 is adapted toengage the top recess 594 of the filter receptacle 512 that includes thevarious tabs 596 and the first and second nozzles 116, 118. In such anembodiment, the blocking flange 518 typically does not extend along thevertical side of the lint filter 510 that is adjacent to the filteraperture 640. Rather, the support portion 660 engages a portion of thebasement 242 to align the lint filter 510 within the airflow path 20 andsecure the lint filter 510 within the filter receptacle 512 disposedwithin the basement 242 of the appliance 12.

Referring again to FIGS. 37-44, the top and bottom recesses 594, 572 aretypically aligned with at least a portion of the filter aperture 640such that the top and bottom recesses 594, 572 cooperatively define asliding channel 680 through which the lint filter 510 can be manipulatedbetween the installed and removed positions 670, 672. The tabs 596 ofthe top and bottom recesses 594, 572 as well as the first and secondnozzles 116, 118 can be used to define the sliding channel 680 andproperly align the lint filter 510 as it is being slidably inserted intothe filter receptacle 512 to define the installed position 670. Where avertical side 522 of the lint filter 510 engages one of the tabs 596 orthe first and second nozzles 116, 118, a person operating the lintfilter 510 receives feedback that the lint filter 510 is properlyaligned within the lint filter receptacle 512. The feedback provided bythe top and bottom recesses 594, 572 helps to ensure that the lintfilter 510 is properly and securely placed within the filter receptacle512. As discussed previously, when the lint filter 510 is in theinstalled position 670 within the filter receptacle 512, the lint filter510 experiences minimal amounts of vibration. In this manner, minimalamounts of noise emanate from the lint filter 510 during operation ofthe appliance 12.

As exemplified in FIGS. 42 and 43, the filter aperture 640 disposedwithin the vertical wall 590 of the basement 242 can include an outerrecess 690 that receives the securing flange 642. The outer recess 690can be used to receive the securing flange 642 of the lint filter 510and inform the user of the appliance 12 that the lint filter 510 isfully installed within the filter receptacle 512. Typically, the gasket650 is disposed within the outer recess 690. This configuration can alsofurther assist in minimizing the amount of vibration experienced by thelint filter 510 during operation of the appliance 12.

Referring now to FIGS. 5-6, 25-29, 45 and 46, condensate 36 that hasbeen removed by the heat exchangers 26 is delivered to the drain channel38. This condensate 36 flows through the drain channel 38 and isdirected to the sump 410 where a sump pump 414 selectively operates todeliver the condensate 36 to other portions of the appliance 12 or outof the appliance 12 for eventual disposal. The sump 410 can also be usedto collect lint particles 64 that have been cleaned from variousportions of the appliance 12. The sump pump 414 that is disposed withinthe sump area 710 can be in the form of a washer-type pump that is ableto move condensate 36 as well as various particulate material, such aslint particles 64, from the sump area 710 to other portions of theappliance 12 for use or disposal. The condensate 36 and the fluid andlint mixture 412 can each be defined as a sump fluid 728 that is movedinto the sump area 710 and transported therefrom by the sump pump 414.The other portions of the appliance 12 that the sump pump 414 candeliver the sump fluid 728 to can include, but are not limited to,various spray nozzles 52, a removable bottle 56, a drum 14, variouscooling functions of the appliance 12, combinations thereof, and othersimilar locations.

Referring again to FIGS. 25-29 and 45-46, the sump area 710 can includea multi-component fluid sensor 720 that controls activation anddeactivation of the sump pump 414. Using a multi-component fluid sensor720, the amount of sump fluid 728 within the sump 410 may be used tocontrol the various operating cycles 722 of the sump pump 414. Themulti-component fluid sensor 720 can include an upper sensor 724 thatdetects when the level of sump fluid 728 reaches a maximum capacity 726.When the sump fluid 728 reaches this maximum capacity 726, the uppersensor 724 triggers activation of the sump pump 414. Once activated, thesump pump 414 delivers at least a portion of the sump fluid 728 from thesump area 710 to another portion of the appliance 12. During operationof a particular drying function 30 of the appliance 12, when the uppersensor 724 detects that the level of condensate 36 is at the maximumcapacity 726, the sump pump 414 will initiate an operating cycle 722 toremove, typically, only that amount of sump fluid 728 to leaveapproximately a minimum capacity 730 of sump fluid 728 within the sumparea 710. This minimum capacity 730 of sump fluid 728 can be used foraccomplishing various spray sequences 160 of the appliance 12, as willbe described more fully below.

When the sump fluid 728 has been detected as being at this maximumcapacity 726, the sump pump 414 activates to remove at least a portionof the sump fluid 728 to a removable bottle 56 or to an external drainto prevent overflow of sump fluid 728 out of the drain channel 38 andalso out of the sump area 710.

Referring again to FIGS. 25-29 and 45-46, the multi-component fluidsensor 720 also includes a lower sensor 740 that detects when the levelof sump fluid 728 reaches the minimum capacity 730. When the level ofsump fluid 728 is below this minimum capacity 730, a control for theappliance 12 can place the sump pump 414 in an idle state 742, such thatthe sump pump 414 is not typically activated. The minimum capacity 730of sump fluid 728 being within the sump pump 414 ensures that anappropriate amount of sump fluid 728 is contained within the sump pump414 for accomplishing a particular spray sequence 160 of the appliance12. Such spray sequences 160 can include a particular cleaning cyclewhere a lint filter 510, coil of a heat exchanger 26, or other surfaceof the appliance 12 is cleaned using sump fluid 728 contained within thesump pump 414.

Where the amount of sump fluid 728 within the sump pump 414 is belowthis minimum capacity 730, there may be an insufficient amount of sumpfluid 728 for accomplishing an uninterrupted spray sequence 160. Whereinsufficient sump fluid 728 exists, operation of a particular operatingcycle 722 of the sump pump 414 may result in the sump pump 414 movingair, rather than the sump fluid 728. The movement of air through thesump pump 414 may result in overexertion of the sump pump 414, wastedenergy, and potentially damage to the sump pump 414 and other portionsof the appliance 12. By ensuring that at least a minimum capacity 730 ofsump fluid 728 is contained within the sump pump 414, themulti-component fluid sensor 720 can be utilized to ensure uninterruptedefficient performance of an operating cycle 722 of the sump pump 414during operation of the appliance 12.

Referring again to FIGS. 25-29 and 45-46, after the amount of sump fluid728 within the sump pump 414 reaches the minimum capacity 730, theminimum capacity 730 of sump fluid 728 is detected by the lower sensor740. Again, the sump fluid 728 may be only condensate 36 or may be thefluid and lint mixture 412 that includes both condensate 36 and lintparticles 64. The lower sensor 740 can then send a signal to a controlto place the sump pump 414 in an activated state 750. In this activatedstate 750, the sump pump 414 is typically able to be activated whereinitiation of a spray sequence 160 of the appliance 12 is necessary orwhere movement of sump fluid 728 from the sump area 710 is necessary,such as when the amount of sump fluid 728 in the sump area 710 reachesthe maximum capacity 726. Again, the multi-component fluid sensor 720may also be used to ensure that the minimum capacity 730 of sump fluid728 is contained within the sump area 710. In this manner, during anoperating cycle 722, the sump pump 414 will have a substantiallycontinuous supply of condensate 36 during a spray sequence 160 and thesump pump 414 will be substantially prevented from pumping quantities ofair, which may cause damage to the sump pump 414.

Referring again to FIGS. 5-6, 25-29 and 45-46, during a particular spraysequence 160 of the appliance 12, the sump pump 414 in the activatedstate 750 is operated to deliver sump fluid 728 to the spray nozzle 52that is used to clean the particulate material such as lint particles 64from a surface of the lint filter 510, or from a surface of a coil of aheat exchanger 26. The spray nozzle 52 can also be used to clean othersurfaces of an appliance 12, such as a heat exchange plate 190, thedrain channel 38, the sump area 170, the drum 14, or other portions ofthe appliance 12. The sump fluid 728 delivered by the sump pump 414 andused to clean the surface of the appliance 12 is then delivered back tothe drain channel 38 and then on to the sump area 170. In this manner,the sump pump 414 may recirculate the sump fluid 728 during performanceof the particular spray sequence 160. As discussed above, to account forthe recirculation of lint particles 64 within the sump fluid 728, thesump pump 414 can be a washer-type pump that is configured to move theseparticles of matter in the form of lint particles 64 and otherparticulate material may be contained within the sump fluid 728. Becausethe sump fluid 728 is recirculated during a particular spray sequence160, it is typically not necessary that additional fluid be added to thesump area 170 to perform the particular spray sequence 160. In thismanner, so long as the minimum capacity 730 of sump fluid 728 iscontained within the sump area 170, the recirculating function of thesump pump 414 for delivering sump fluid 728 to the spray nozzles 52 istypically sufficient to accomplish the entire spray sequence 160.

Referring again to FIGS. 5-6, 25-29 and 45-46, at the completion of aparticular drying function 30, a certain amount of sump fluid 728 willtypically be contained within the sump area 170. This sump fluid 728, atthe end of the drying function 30 will be moved by the sump pump 414 toa separate area of the appliance 12 for disposal. This separate area maybe in the form of the removable bottle 56 or may be an outlet for movingthe sump fluid 728 to an external drain outside of the appliance 12.During this final drain operation 760 at the end of the drying function30, a signal is provided, typically by a control, to initiate anoverride 762 to the multi-component fluid level sensor 460. Thisoverride 762 allows the amount of sump fluid 728 within the sump area170 to drop below the minimum capacity 730 while maintaining operationof the sump pump 414 for removing the sump fluid 728 from the sump area170 to after completion of the drying function 30. This override 762 canalso be in the form of a deactivation or suspension of themulti-component fluid sensor 720. In either instance, the sump pump 414may be activated when the level of sump fluid 728 within the sump pump414 is above or below the minimum capacity 730 that is detectable by thelower sensor 740 of the multi-component fluid sensor 720.

According to various aspects of the device, the multi-component fluidsensor 720 can be in the form of a single elongated member with aplurality of sensors disposed thereon. Along the elongated member, theupper and lower sensors 724, 740 and other intermediary sensors may alsobe located on the single member. When the sump fluid 728 engages aparticular portion of the multi-component fluid sensor 720, variouscommunications can be sent to a control or directly to the sump pump 414for defining the activated and idle states 750, 742 and also foroperating the sump pump 414 during and after performance of a particulardrying function 30. In various aspects of the device, themulti-component fluid sensor 720 can include separate members that arespaced at different locations within the sump area 170. These locationscan be indicative of different levels of sump fluid 728 that correspondto at least the minimum capacity 730 and maximum capacity 726 of thesump area 170.

In various aspects of the device, the multi-component fluid sensor 720can provide information regarding other levels of sump fluid 728 withinthe sump area 170. In addition to the minimum and maximum capacity 730,726, additional portions of the multi-component fluid sensor 720 canprovide information concerning the amount of sump fluid 728 that may beneeded for separate spray sequences 160. By way of example, and notlimitation, a spray sequence 160 for cleaning a lint filter 510 mayrequire a different amount of sump fluid 728 than a spray sequence 160for cleaning the coil of a heat exchanger 26 or a spray sequence 160 forcleaning a surface of a heat exchange plate 190. Additionally,components of the multi-component fluid sensor 720 may be used fordeactivating the sump pump 414, such as during operation of the sumppump 414 for removing excess sump fluid 728 when the level of sump fluid728 within the sump area 710 reaches the maximum capacity 726. In suchan embodiment, the lower sensor 740 may detect when the level of sumpfluid 728 within the sump area 170 being pumped away from the sump area170 reaches the minimum capacity 730. At this minimum capacity 730, thelower sensor 740 may deactivate the sump pump 414 to maintain thisminimum capacity 730 of sump fluid 728 within the sump area 170.Additional portions of the multi-component fluid sensor 720 can beincorporated for accomplishing similar functions for activating anddeactivating the sump pump 414 and also for placing the sump pump 414 inthe activated and idle states 750, 742.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A fluid flow system for a laundry appliance, thefluid flow system comprising: a blower that delivers process air alongan airflow path during performance of a drying operation; a heatexchanger for dehumidifying the process air and removing condensatetherefrom; a lint filter for capturing lint particles from the processair, wherein a fluid spray system removes the lint particles from thelint filter; a sump that collects the condensate from the heat exchangerand lint particles from the fluid spray system to define sump fluidwithin the sump; and a sump cover having a pump that directs the sumpfluid from the sump and to a fluid diverter valve, and a fluid levelsensor that at least partially operates the pump; wherein the pump andthe fluid level sensor are directly attached to the sump cover; the pumpactivates when a level of the sump fluid reaches a maximum capacitywithin the sump; and the pump remains idle when the level of the sumpfluid is below a minimum capacity.
 2. The fluid flow system of claim 1,wherein the fluid level sensor is deactivated and the pump is activatedduring a drain phase of the pump when the drying operation is complete.3. The fluid flow system of claim 1, wherein the fluid diverter valve isselectively operable to direct the sump fluid to a spray nozzle during aspray sequence, wherein the spray sequence operates to recirculate thesump fluid, sequentially, through the sump, the pump, the fluid divertervalve, the spray nozzle and returning to the sump.
 4. The fluid flowsystem of claim 3, wherein the spray sequence is performed after thelevel of the sump fluid in the sump reaches the minimum capacity.
 5. Thefluid flow system of claim 4, wherein the minimum capacity of the sumpfluid in the sump defines an amount of sump fluid that defines acontinuous supply of the sump fluid through the pump during performanceof the spray sequence.
 6. The fluid flow system of claim 2, whereinduring the drain phase, the sump fluid is directed from the pump to aremovable bottle, wherein the sump cover includes an integral overflowport that is in communication with the removable bottle, wherein whenthe sump fluid in the removable bottle exceeds a full capacity, the sumpfluid is directed into the sump via the integral overflow port.
 7. Thefluid flow system of claim 1, wherein the sump includes a cup portionthat defines a fluid inlet and an impeller chamber, wherein the fluidinlet and an impeller chamber are in communication with a fluid outlet,wherein the impeller of the pump rotates within the impeller chamber. 8.The fluid flow system of claim 6, wherein the fluid level sensor iscoupled to a control that operates the pump, wherein the pumpselectively operates according to an override that is independent of thefluid level sensor; wherein: the override activates the pump when thelevel of the sump fluid is below the minimum capacity at completion ofthe drying operation; and the pump is deactivated when the sump fluid inthe sump reaches the maximum capacity and the sump fluid in theremovable bottle reaches the full capacity.
 9. The fluid flow system ofclaim 1, wherein the fluid level sensor includes a multi-part sensorthat includes a lower sensor and an upper sensor; wherein: the lowersensor detects when the sump fluid in the sump reaches the minimumcapacity; and the upper sensor detects when the sump fluid in the fluidlevel sensor reaches the maximum capacity.
 10. A method for operating afluid flow system for an appliance, the method comprising steps of:performing a drying operation; delivering sump fluid to a sump, the sumpfluid including condensate from a heat exchanger and lint particles froma fluid spray system; detecting a level of the sump fluid in the sump,wherein a sump pump remains idle during the drying operation when thelevel of the sump fluid is below a minimum capacity; performing a spraysequence after the level of the sump fluid reaches the minimum capacity,wherein the spray sequence directs the sump fluid to remove the lintparticles from a surface and direct the lint particles and the sumpfluid to the sump; recirculating the sump fluid containing the lintparticles during the spray sequence, wherein the sump fluid is directedfrom the sump, to a spray nozzle via a fluid diverter valve, and back tothe sump; completing the spray sequence; completing the dryingoperation; and operating a drain phase of the sump pump to deliver thesump fluid to a removable bottle after completion of the dryingoperation.
 11. The method of claim 10, further comprising: performing anoverride phase at the completion of the drying operation, wherein theoverride phase includes pumping fluid to a fluid outlet.
 12. The methodof claim 11, wherein the override phase includes a temporary suspensionof the step of detecting a level of the fluid in the sump.
 13. Themethod of claim 11, wherein the override phase is further defined byoperation of the sump pump to deliver fluid to the fluid outlet when thesump defines a maximum capacity and the removable bottle defines a fullcapacity.
 14. A fluid flow system for a laundry appliance, the fluidflow system comprising: a sump that collects fluid from a drain channel,wherein the fluid at least partially includes condensate from a heatexchanger; a pump that directs the fluid from the sump and to one of afluid outlet and a removable bottle; and a fluid level sensor thatdetects at least a minimum capacity and a maximum capacity of the fluidin the sump, wherein: typical operation of the pump is defined by anidle state when the fluid is below the minimum capacity and an activestate when the fluid reaches the maximum capacity; and an overrideoperation of the pump is defined by a suspended operation of the fluidlevel sensor when a level of the fluid is below the minimum capacity atcompletion of a drying cycle, and when the fluid in the sump reaches themaximum capacity and the fluid in the removable bottle reaches a fullcapacity.
 15. The fluid flow system of claim 14, further comprising: asump cover that includes a pump seat that receives the pump and a fluidoutlet that is integrally formed in the sump cover.
 16. The fluid flowsystem of claim 15, wherein the fluid level sensor is disposed withinthe sump cover.
 17. The fluid flow system of claim 16, wherein the fluidlevel sensor includes a multi-component sensor that includes a lowersensor and an upper sensor, wherein: the lower sensor detects when thefluid in the sump reaches the minimum capacity; and the upper sensordetects when the fluid in the fluid level sensor reaches the maximumcapacity.
 18. The fluid flow system of claim 14, wherein the pump isselectively operated to deliver fluid from the sump to a spray nozzle,via a fluid diverter valve, during performance of a spray sequence,wherein the fluid from the spray nozzles is directed into the drainchannel and is recirculated back to the sump to define recirculated sumpfluid, wherein the pump directs the recirculated sump fluid to the spraynozzles via the fluid diverter valve until completion of the spraysequence.
 19. The fluid flow system of claim 15, wherein the sump coverincludes an integral overflow port that is in communication with theremovable bottle, wherein excess fluid from the removable bottle isdirected into the sump via the integral overflow port.
 20. The fluidflow system of claim 18, wherein the recirculated sump fluid includesthe condensate from the heat exchanger and lint particles from anupstream surface of a lint filter.